Service Bulletin 03-2009_en
Contents
1. Start to mount the parts in reversed order Please use the torques from the table below or from the Service Manual 2009 p n 2258 379 Fill the front differential with the front differential oil supplied by Arctic Cat to the filling level as required after assembling see Service Manual 2009 p n 2258 379 pages 1 2 pages 2 10 A ARCTIC CAT Bulletin Nr 03 2009 oe page 10 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft Model Thundercat MY 2008 Tightening torque table torque Part bolted with Nm ae gn tae Oil drain screw Front differential case 5 front differential case Fill up plug screwin a 9 front differential case 22 front differential case Output yoke nut Driven output shaft Please only use original Arctic Cat spare parts fixings for the assembling Always use undamaged not deformed securing pins for the securing screwing which should be correct to the designated borehole and fitting length For mounting the brake callipers use new screws If you reuse the demounted screws from the brake callipers you have to use Loctite for securing them Pay attention to the existence of screw securing means when using new SCrews A ARCTIC CAT Bulletin Nr 03 2009 page 11 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft Model Thundercat MY 2008 Advise Note the Service Bulletin in the service booklet of the ATV Refund After comple2. Service Bulletin ARCTIC CAT Date September 2009 Subject Front Gear Case and Front Drive Shaft Model Thundercat MY 2008 Bulletin Nr 03 2009 Model Model Year Thundercat H2 MY 2008 Chassis number control 4UFO8ATV48T2 F AUFO8ATV58T24 H e AUFO8ATV68TS HH e 4UFO8ATVX8T2 F Within this Service Bulletin the front differential has to be changed on the Arctic Cat Thundercats mentioned above Arctic Cat gives you the chance to increase the value of your Thundercat or the Thundercat of your costumers from MY 2008 to the current Standards of MY 2010 The front drive shaft and the U Joint cross have to be changed as well Rebuilding range Change the front differential by using the conversion kit front differential p n 1502 281 Mount the new front drive shaft 1502 342 Dringlichkeit low within the next service interval Material 1 Conversion kit front diferential p n 1502 281 2 Short front drive shaft p n 1502 342 3 U Joint p n 1502 325 4 U Joint cross p n 0402 944 see fig 1a and fig 1b on page 2 Bulletin Nr 03 2009 page 1 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft Model Thundercat MY 2008 Fig 1a Thundercat Front Gear Case Fig 1b U Joint cross U Joint and drive shaft short Bulletin Nr 03 2009 page 2 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft Procedur ATTENTION Demount 1 Advise
3. page 7 2 chapter Shock Absorber Separate the knuckles from the front axle drive shaft see fig 9 See Service Manual 2009 2258 379 page 6 4 Removing Differential chapter 10 13 Fig 9 Demounting Axle Put the front axle drive shaft horizontally to the front differential Protect the axle from falling down because a too high angle of the front axle drive shaft may lead to irreparable damages Make sure that the upper and lower A Arms dont fall down Risk of injury and or damage Secure the loosened shock absorbers Remove the screwing of the lower and upper A Arms and demount them You need an Arctic Cat Special Tool for the following working step Slide Hammer the p n is 0444 225 Remove the front axle drive shaft from the front axle case by using the special tool Slide Hammer see fig 10 page 8 Aaa CAT page 7 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft Hinweis Bulletin Nr 03 2009 Model Thundercat MY 2008 Pay attention on the right position of the special tool Using it in a wrong way may cause damage to the vehicle itself the axle the front differential case and the axle boot Demount the 2WD 4WD switch unit see Service Manual 2009 p n 2258 379 page 6 5 chapter 17 and following Disconnect the connectors Demount the operation of the front differential lock Remove the aeration of the front differential case Loosen and remov
4. Model Thundercat MY 2008 Switch off the ignition before beginning with the Service Bulletin Off Position and disconnect the battery see Service Manual Arctic Cat 2009 PN 2258 379 page 5 3 and the engine and exhaust pipe have to be cold risk of getting burned Lift the vehicle to allow the front wheels to be removed Make sure that the vehicle cannot overturn or move Remove the front wheels by using the Service Manual 2009 p n 2258 379 page 7 7 chapter Wheels and Tires Using the Arctic Cat Service Manual 2009 p n 2258 379 is compulsory for all the following working steps Removing the front differential is described in the Service Manual 2009 p n 2258 379 on page 6 3 chapter Removing Differential Remove the oil drain screw see Fig 2 on page 4 from the front differential case and the fill up plug Make sure that the gear oil is disposed of as instructed by the environmental regulation Bulletin Nr 03 2009 oa page 3 from 12 Subject Front Gear Case and Front Drive Shaft Date September 2009 Model Thundercat MY 2008 Front Differential woe _ _ M i Oil drain screw aie git Pres w f A ek je SN CE ig A S N ff Fig 2 oil drain screw front differential Use the Service Manual 2009 2258 379 page 7 3 chapter Front Arms and the work specifications below for the following working steps Remove the cotter pins see fig 3 on page 4 a
5. e the screwing of the front differential case Make sure that the front differential case does not fall onto lower crossbar Move the front differential case forward in the direction of the radiator assembly You can now remove it sideways from the short axle drive shaft between engine and front differential Turn the front differential case by 90 see fig 11 on page 9 Takar page 8 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft Model Thundercat MY 2008 Fig 11 Demounting Front Gear Case 6 Replace the removed front differential Front Gear Case ASSY with the front differential from the conversion kit Advise You need an Arctic Cat Special Tool for the following working step The special tool U Joint Separator Tool with the p n 0444 225 7 For demounting the short drive shaft the front U Joint cross has to be removed Remove the securing clips for this working step see fig 12 Fig 12 Removing the securing clips Bulletin Nr 03 2009 page 9 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft 10 11 Model Thundercat MY 2008 Demount the U Joint cross after removing all the securing clips by using the special tool U Joint Separator Tool Loosen and remove the castle securing nut of the front U Joint see fig 13 Fig 13 castle nut front U Joint Change the demounted U Joint with the U Joint from the conversion kit
6. nd fig 4 on page 5 from the front wheel hub left and right Loosen the castle nuts Aa on Castle nut and cotter pin sna Fig 3 castle nut with cotter pin EET page 4 from 12 Bulletin Nr 03 2009 Date September 2009 Subject Front Gear Case and Front Drive Shaft Model Thundercat MY 2008 Fig 4 Removing of cotter pin Demount the brake callipers see fig 5 on page 5 Make sure that the brake hose Is not cracked Attention Support the brake calliper do not let it hang on the brake hose Strain relief n o gt ae s ST Lit herr nt Fig 5 Screwing of Brake Calliper Remove the wheel hubs and the brake discs Remove the cotter pins of the lock nuts for the tie rods Loosen the castle nuts and swing the tie rods aside Fig 6 and 7 on page 6 Amar Bulletin Nr 03 2009 page 5 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft Model Thundercat MY 2008 Fig 7 Loosening the tie rod screwing Remove the ball joint screwing from the knuckles see fig 8 Fig 8 Loosening the ball joint screwing ZSE Bulletin Nr 03 2009 ARCTIC CAT page 6 from 12 Date September 2009 Subject Front Gear Case and Front Drive Shaft Attention Advise Bulletin Nr 03 2009 Model Thundercat MY 2008 Swing the upper and lower A Arm out of the knuckles Remove the screws from the shock absorber on the upper knuckle see Service Manual 2009 2258 379
7. tion of this work please send a warranty claim containing a working time of 108 min and the p n of the conversion kit Please submit a separate claim for each repaired vehicle ACHTUNG Only completely filled out warranty claims can be accepted If you do not send back the old party we won t accept the warranty claim Submit the warranty claim and the parts within 30 days after completing the service bulletin to Arctic Cat Warranty Claims which are submitted later will be rejected The dealer is responsible for assuring that the necessary service for all concerned ATVs is accomplished according to the instructions which are enclosed in this message This service must be accomplished before handing out a concerned ATV to a customer Bulletin Nr 03 2009 oa page 12 from 12
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